U.S. patent number 10,041,725 [Application Number 15/044,676] was granted by the patent office on 2018-08-07 for mobile cabinet with insulation.
This patent grant is currently assigned to INTERMETRO INDUSTRIES CORPORATION. The grantee listed for this patent is InterMetro Industries Corporation. Invention is credited to James Dube, Wilhelm Heinrich, Jeffrey Olson, Willard Sickles.
United States Patent |
10,041,725 |
Olson , et al. |
August 7, 2018 |
Mobile cabinet with insulation
Abstract
A mobile cabinet may include a cabinet body, a door, a heating
or refrigeration module, and at least one attachable insulation
panel. The insulation panel may be a single panel, or a plurality
of panels, to provide insulation for the cabinet. The insulation
panel may include a hinge to couple multiple wall sections that can
be attached to different walls of the cabinet and integral hand
holds.
Inventors: |
Olson; Jeffrey (Dallas, PA),
Heinrich; Wilhelm (White Haven, PA), Sickles; Willard
(Dalton, PA), Dube; James (Scranton, PA) |
Applicant: |
Name |
City |
State |
Country |
Type |
InterMetro Industries Corporation |
Wilkes-Barre |
PA |
US |
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Assignee: |
INTERMETRO INDUSTRIES
CORPORATION (Wilkes-Barre, PA)
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Family
ID: |
56622341 |
Appl.
No.: |
15/044,676 |
Filed: |
February 16, 2016 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160238303 A1 |
Aug 18, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62117332 |
Feb 17, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B
31/02 (20130101); F25D 23/063 (20130101); A47J
39/006 (20130101); F25D 3/06 (20130101); F25D
2400/20 (20130101) |
Current International
Class: |
A47J
39/00 (20060101); A47B 31/02 (20060101); F25D
23/06 (20060101) |
Field of
Search: |
;312/400,406,257.1,258,262,249.8 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
International Search Report and Written Opinion in International
Application No. PCT/US2016/018069, dated Apr. 21, 2016. cited by
applicant.
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Primary Examiner: Hansen; James O
Attorney, Agent or Firm: Harness, Dickey & Pierce,
P.L.C.
Claims
The invention claimed is:
1. A mobile cabinet comprising: a cabinet body including a front,
first and second side walls and a back wall, each of the first and
second side walls having a depth, and the back wall having a width;
a door attached to the front of the cabinet body; and two
insulation panels attachable to the cabinet body; wherein each of
the insulation panels includes a side wall section, a back wall
section, a hinge comprising a first hinge portion and a second
hinge portion connecting the side wall section and the back wall
section, and a flange that projects perpendicularly from a front
edge of a respective side wall, opposite the hinge; wherein the
side wall section includes an angled surface proximate to the first
hinge portion and the back wall section includes an angled surface
proximate to the second hinge portion; and wherein the side wall
section and the back wall section of each of the insulation panels
is, respectively, folded about the first hinge portion and the
second hinge portion in an L-shape and each insulation panel wraps
the cabinet body over a portion of the front of the cabinet body
that is proximate to the door, a depth of one of the first and
second side walls and a portion of the width of the back wall, and
the respective angled surfaces of the side wall section and the
back wall section are spaced apart by a distance; wherein the
flange extends beyond a front end of the respective side wall and
wraps around the front corner to cover a portion of the front of
the cabinet body that is proximate to the door; and wherein the
insulation panel comprises a rounded seamless surface on an
exterior side of the insulation panel at the hinge.
2. The mobile cabinet of claim 1, wherein each insulation panel
includes at least one hand hold integrally formed in the side wall
section.
3. The mobile cabinet of claim 1, wherein the hinge in each
insulation panel is integrally formed with the side wall section
and the back wall section.
4. The mobile cabinet of claim 1, wherein the side wall section,
the back wall section, and the hinge of each insulation panel are
integrally formed, and wherein each of the side wall section and
the back wall section defines a cavity that is filled with an
insulating material.
5. The mobile cabinet of claim 4, wherein the hinge, the side wall
section, and the back wall section are formed by a one of a blow
molding process and a rotational molding process.
6. The mobile cabinet of claim 1, wherein the back wall section of
each insulation panel includes a flange that projects from a side
of the back wall section opposite the hinge.
7. The mobile cabinet of claim 1, wherein the hinge is an
integrally molded section attaching the side wall section to the
back wall section so as to space apart the side wall section and
back wall section from each other when the insulation panel is laid
flat.
8. The mobile cabinet of claim 7, wherein the first hinge portion
and the second hinge portion are connected by a web portion wherein
the the rounded seamless surface on the exterior side of the
insulation panel comprises the web portion.
9. The mobile cabinet of claim 8, wherein the first hinge portion
and second hinge portion enable the side wall section and the back
wall section to move independently from one another and in a
direction perpendicular to one another when the insulation panel is
folded in the L-shape.
10. A mobile cabinet comprising: a cabinet body including a front,
a side wall and a back wall; a door attached to the front of the
cabinet body; and at least one insulation panel attachable to the
cabinet body for covering at least a portion of both the side wall
and the back wall of the cabinet body, the insulation panel
comprising a side wall section, a back wall section, and a double
living hinge integrally formed with, disposed between and
connecting the side wall section and the back wall section; wherein
the hinge comprises a first hinge portion and a second hinge
portion that are connected by an intermediate web portion, wherein
the first hinge portion the second hinge portion and the web
portion cooperatively enable independent movement of the side wall
section in a direction parallel to the side wall and the back wall
section in a direction parallel to the back wall while attaching
the insulation panel to the cabinet body; wherein an exterior
surface of the insulation panel at the hinge comprises a rounded
seamless surface comprising the web portion; and wherein the
insulation panel further comprises means for preventing burns to a
user located at the front of the cabinet body proximate to the
door.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to mobile cabinets with
insulation.
Background
For restaurants, schools, hospitals, etc. where food and drink are
served, it is often not possible for a kitchen to prepare enough
servings from scratch to feed everyone within a reasonable time
period. Accordingly, food and drink items are prepared ahead of
time and stored until served. To ensure that items do not perish or
reach an undesired temperature, they are typically stored in mobile
or stationary cabinets. The food is prepared and loaded into the
cabinets, which are plugged into an electrical outlet so that
internal heating systems can heat, or refrigeration system can
cool, the interior of the cabinet. Mobile cabinets can be moved to
facilitate cleaning the floor underneath them. Similar cabinets may
also be used in hospitals, schools or other environments where
meals are prepared at a central location and substantial time may
lapse before they are ultimately delivered to the intended
destinations, e.g. remote patient rooms.
Traditionally, holding cabinets fell into two general categories
related to performance: insulated and un-insulated. Un-insulated
cabinets generally fall into a "budget" category of cabinet, are
inefficient, and may have hot exteriors. Insulated cabinets are
typically manufactured by creating inner and outer sheet metal
shells, with some form of insulation between them. These cabinets
may provide good insulation performance and structure, but the
process of manufacturing them is time consuming. Most insulated
cabinets employed a fiberglass bat or board insulation that was
easier, and less expensive to assemble, but the insulation could
absorb moisture over time, losing its efficacy. In addition
cabinets with metal outer surfaces are susceptible to denting,
scratching, and require bumpers to be added to prevent damage to
the cabinet or to the facility itself when moving the cabinet.
The conventional un-insulated cabinets have several other
drawbacks. The metal exteriors of these cabinets transfer heat, and
may lead to user burns. In addition, moving the cabinets inevitably
results in bumps and vibrations which can harm the exterior of the
cabinets or interior mechanical systems. Some cabinets have
addressed these problems with padded and/or insulated hand holds,
but these hand holds usually leave many exposed surfaces, including
surfaces near the front of the cabinets that may lead to user
burns.
Consequently, it would be advantageous to provide a cost-effective
mobile cabinet which addresses the problems arising from a lack of
expensive integrated insulation. It would also be advantageous to
provide a mobile cabinet with insulation that protects the cabinet
from harmful bumps and vibrations. In addition, it would be
advantageous to design a mobile cabinet where the user is protected
from possible burns through improved safety. In addition, it is
also be advantageous to provide a mobile cabinet that complies with
ENERGY STAR.RTM. requirements.
SUMMARY OF THE INVENTION
The present invention provides a mobile cabinet with an attachable
insulation panel system.
In one embodiment, the mobile cabinet may include a cabinet body, a
door, a heating or refrigeration module, and at least one
attachable insulation panel. The insulation panel may be a single
panel which is formable around the entire cabinet, or a plurality
of panels may be used to provide insulation for the cabinet to
allow the cabinet to comply with ENERGY STAR.RTM. requirements, by
improving the amount of coverage of an inner shell, reducing
exposed hot areas, improving safety and efficiency. The insulation
panel may also provide integral hand holds that allow easier moving
and handling.
In a preferred embodiment, the insulation for the cabinet may be a
system of panels. The system of panels is preferably between two
and four insulation panels. For small size cabinets, the system of
panels is preferably two panel sections, which each wrap the
cabinet from a front corner to at least a middle of the back of the
cabinet, in an L-shape. In a preferred embodiment, the insulation
panel sections are coupled by a hinge. For larger size cabinets,
the system of panels is preferably four insulation panels, which
each wrap either the top or bottom part of the cabinet from a front
corner of the cabinet to at least the middle of the back of the
cabinet, in an L-shape. A plurality of panels can be mounted on
each side of the cabinet. In another preferred embodiment, the
insulation panel may have three sections connected by two hinges,
such that the insulation panel can wrap around three sides of the
cabinet.
The insulation panels preferably include a side wall section and a
back wall section. The side wall section provides insulation to the
side wall from the front of the cabinet near the door to the back
of the cabinet. The back wall section provides insulation to the
back of the cabinet and may extend from the back of the side wall
to about the center of the rear wall of the cabinet.
The insulation panel may be formed with a side wall section that
substantially covers the side wall of the cabinet and a back wall
section that covers about half (or a portion) of the back wall of
the cabinet. With such a construction, two hinged insulation panels
can wrap the cabinet body from the position of the door back to a
position where the panels meet near the center of the back wall of
the cabinet.
The hinged panels may be formed to wrap around the entire cabinets,
or multiple hinged panels may be used together in order to surround
the cabinet. The hinge may be formed as an integral part of the
panel. In a preferred embodiment, the hinge may be a double living
hinge that is formable during a blow molding process. A single
panel may be used to surround only half of the cabinet. The hinged
panel may also include a single hinge or a plurality of hinges. The
hinge may also be omitted from the design. That is, the insulation
panels may be formed as a series of panels without hinges that may
be secured to each other, or as a single panel with a plurality of
hinges that allows the panel to bend around both rear corners of
the cabinet. An extruded insert may also be used to couple multiple
panels together.
In a preferred embodiment, the insulation panel includes a flange
that is formed to extend substantially perpendicular to the length
of the panel. The flange may extend from a position proximate to a
front edge of a side wall section. The flange may be formed to
provide coverage to the front portion of the cabinet proximate to
the door. The flange may include openings for securing the panel to
the cabinet with screws or other securing members. The flange
provides additional insulation for the cabinet and protection to
the user of the cabinet.
The insulation panels may be fastened to a single-walled cabinet to
create a high-performance insulated cabinet with improved
aesthetics and usability. The insulation panels may be attached to
the cabinet using screws from the interior of the cabinet. The
insulation panels may also be attached to the cabinet through
mounting portions formed in the insulation panels. Mounting
portions are preferably provided in the flange to secure the panel
to the front of the cabinet.
Mounting portions may also be provided in the back wall section of
the insulation panel, to attach the insulation panels to the rear
of the cabinet, preferably near the edge of the back wall section.
In a preferred embodiment, the cabinet is provided with a raised
channel on the back of the cabinet. The raised channel preferably
runs down the center of the back and allows the insulation panels
to be secured thereto without penetrating the back of the cabinet.
Screws that penetrate the cabinet walls may create a leak of
thermal energy and/or create a dirt trap in the food storage space.
As such, the raised channel allows the insulation panels to be
secured to the cabinet without affecting the R value of the
cabinet. In a more preferred embodiment, the back wall section of
the insulation panel includes a cutout to accommodate the raised
channel. The cutout is preferably shaped to allow the insulation
panels to be secured flush to the raised channel.
The insulation panels may be provided in multiple sizes, which are
usable together with cabinets of different heights. The insulation
panels may be provided to In a preferred embodiment, the insulation
panels are between 18 and 32 inches in height. In a more preferred
embodiment, the insulation panels are between 19 and 29 inches in
height.
In order to provide the best insulation and protection, it is
preferable that the insulation panel be as thick as possible.
However, the insulation panel should not be made thicker than
necessary, which would result in wasted materials and a cabinet
that is difficult to pass around obstacles or through doorways.
Preferably, the maximum thickness of the insulation panel is
between 1.5 and 3 inches. In a preferred embodiment, the maximum
thickness of the insulation panel is between 1.7 and 2.75 inches.
In a more preferred embodiment, the maximum thickness of the
insulation panel is between 1.8 and 2.2 inches.
Of course, the thickness of the panel may vary throughout the width
of the panel to accommodate aesthetic design features or functional
enhancements to the insulation panel. The panel may include a hand
hold or a plurality of hand holds. The hand holds may be formed in
the panel by defining a depression along the height of the
insulation panel, proximate to the front corner of the side panel.
Preferably, the handholds may be formed only on the front side of
the insulation panel, or on both the front and rear sides of the
insulation panel on the side of the cabinet. Additional hand holds
may be formed in the insulation panel on the back of the cabinet.
Preferably, the depth of the hand holds is no more than half the
maximum thickness of the insulation panel.
The insulation panels may be formed from a blow-molding process. In
a preferred embodiment, the insulation panels are multi-part panels
and the blow molding process is used to form an outer shell of the
insulation panels. The insulation panel shells may be filled with
an insulation material. The insulation panel shells are preferably
formed of thermoplastic polymer, such as polyethylene,
polypropylene, or other olefin materials. In addition, the
insulation panels are preferably formed as a shell that may be
filled with insulation. In a preferred embodiment, the insulation
panel is manufactured as a flat, unfolded panel that is deformable.
That is, the panel is preferably formed substantially in one plane,
with a hinge that allows the panel to be secured to at least two
different sides of a cabinet. The insulation panels are preferably
formed in a vertical orientation, in order to align the grain of
the thermoplastic polymer in the hinge portion and maximize the
strength of the insulation panels. The thermoplastic polymer shells
may then be stored as sheets for later filling with insulation
and/or installation onto a cabinet and/or transportation within or
between manufacturing facilities.
Alternatively, the insulation panels may also be formed through a
rotational molding process. The rotational molding process may be
used to form an outer shell by rotating a heated hollow mold. As
another alternative, a sheet molding may be used. The sheet molding
process may be used to create a shell including at least an inner
shell portion and an outer shell portion. The sheet molded shell
portions can then be applied to preformed insulation sheets.
The insulation panel shells may be filled with insulation. In a
preferred embodiment, the shells are filled with polyurethane foam
or an expanded polypropylene (EPP) using a process such as a JSP
FOAMCORE process. The polyurethane foam may be filled into
previously molded insulation panel shells. The filled shells may be
stored and transported in an unfolded state, to maximize space
utilization prior to the installation of the panel onto a cabinet.
Alternatively, the shells may also be filled with fiberglass
insulation. As yet another alternative, the entire insulation panel
may be formed using an expanded polypropylene (or similar
material), without a secondary material.
The cabinet body includes four side defined by three or more walls
which may be formed of at least one layer of sheet metal.
Preferably, the walls of the cabinet body are formed by multiple
layers of sheet metal. The multiple layers of sheet metal may
include an inner layer and an outer layer, with a cavity (or gap)
therebetween. The cavity between the walls may be filled or
provided with insulation. Most preferably, the cabinet body is
mobile, and is provided with wheels or casters on the bottom of the
cabinet.
The heating or refrigeration system is a modular unit provided on
the top or bottom of the cabinet, which provides heating or cooling
to the cabinet through blown air. Alternatively, the cabinet may be
provided without a heating or refrigeration system. Such a cabinet
may include another insulation panel on the top of the cabinet, or
may include an air movement system for maintaining uniform air
temperatures throughout the cabinet without additional heating or
cooling. In a preferred embodiment, the heating or refrigeration
module includes a sheet metal cover. The cover is preferably formed
to extend past the base of the heating or refrigeration module to
act as a panel securing member. The panel securing member may be
formed to cover the top edge of a panel and hold the top edge of
the panel against the cabinet body.
The cabinet may also include at least one chimney along the sides
or back of the cabinet to allow air to be moved from the top to
bottom of the cabinet or, if the cabinet is provided with a bottom
mounted heating or cooling module, to allow air to be moved from
the bottom to the top of the cabinet. In a more preferred
embodiment, the chimney is provided on both sides of the
cabinet.
In a preferred embodiment, the chimney may be thermally isolated
from the side walls of the cabinet. The chimney may have an
interior wall that is spaced from the side wall of the cabinet in
order to provide isolation from the surface in contact with the
insulation and to allow the side wall of the cabinet to create an
additional reflective surface for reflecting heat back into the
center of the cabinet.
The interior of the cabinet may include a plurality of racks for
accepting food service trays or the like. In addition, the interior
of the cabinet is preferably shaped to accept food trays.
Further features and advantages of the present invention will
become more apparent from the detailed description set forth below
when taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are external perspective views of a mobile cabinet
according to one embodiment.
FIG. 2 is an exploded external perspective view of a mobile cabinet
according to one embodiment.
FIG. 3 is an external perspective view of an unfolded cabinet
insulation panel according to one embodiment.
FIG. 4 is an external perspective view of a folded cabinet
insulation panel according to one embodiment.
FIG. 5 is an external top view of an unfolded cabinet insulation
panel according to one embodiment.
FIG. 6 is a cross-sectional top view of an unfolded cabinet
insulation panel according to one embodiment.
FIGS. 7A and 7B are enlarged cross-sectional views of an insulation
panel double living hinge according to one embodiment.
FIGS. 8A and 8B are a cross sectional view of a mobile cabinet, and
an enlarged view of an isolated cabinet chimney according to one
embodiment.
FIG. 9 is a perspective view showing heat flow in a mobile cabinet
according to one embodiment.
FIG. 10 is a perspective view of one corner of a mobile cabinet
with a cutaway of a side panel according to one embodiment.
FIG. 11 is a perspective view of an ambient mobile cabinet without
a heating or cooling module according to one embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Overview
The example embodiments of the invention presented herein are
directed to mobile heated or refrigerated cabinets. This is for
convenience only, and is not intended to limit the application of
the present invention. In fact, after reading the following
description, it will be apparent to one skilled in the relevant art
how to implement the following invention in alternative
embodiments, involving, for example, mobile carts, storage
containers, and refrigerators.
FIGS. 1A and 1B are perspective views of a mobile cabinet 10
according to one embodiment of the invention. The mobile cabinet 10
includes a heating or cooling module 20 located above a storage
space 30. Alternatively, the storage space 30 may be located above
the heating or cooling module 20. The storage space 30 is designed
to store items, while the heating or cooling module 20 is designed
to accommodate a heating or refrigeration system. The lower edge of
the heating or cooling module 20 extends over the top of the upper
insulation panels 112a and 112b.
The sides of the mobile cabinet 10 are wrapped with insulation
panels around the storage space 30. In FIG. 1, the cabinet is
wrapped with four insulation panels, each of which covers the top
or bottom and right or left side of the storage space. The
insulation panels 112 are each hinged panels, which include side
wall sections 114 and rear wall sections 116. The side wall
sections cover the side wall and include a flange portion which
extends across a portion of the front of the cabinet near the door
40. The rear wall sections are coupled to the side wall sections by
a hinge, and extend across a portion of the rear wall of the
cabinet. As shown in FIG. 1A, the rear wall sections of the left
and right insulation panels are both secured to the cabinet near
the center of the rear wall of the cabinet.
FIG. 2 is an exploded external view of an exemplary embodiment of a
mobile cabinet 10 according to the present invention. The mobile
cabinet 10 includes: two sides walls 104a and 104b, a rear wall
105, a door 40 with a latch mechanism 108, an electrical connection
port 109 (not shown in FIG. 2), a user interface 110, upper
insulation panels 112a and 112b, casters 118a-d, lower insulation
panels 112c-d, and insulation panel handles 150.
The door 40 is constructed from two pieces of sheet metal joined
together around a skeletal structure which creates a door cavity.
The door cavity is filled with an insulating material. In one
embodiment, the insulator is polyurethane foam which is a poor
conductor of heat. The polyurethane foam may be injected into the
door cavity, resulting in a relatively homogenous distribution. One
advantage of polyurethane foam, as compared to fiberglass
insulation, is that the foam is sprayed into the door cavity and
then rapidly expands to fill the cavity. The foam effectively
blocks air migration through the door cavity. As a result, minimal,
if any, heat transfer via convection through the door 40 itself
occurs. When the polyurethane foam cures and hardens, it provides
significant torsional rigidity and strength to the door 40. As a
result, the door 40 skeletal structure is less extensive than
conventional mobile refrigeration cabinets, resulting in an overall
reduction in weight.
The side walls 104a and 104b, the rear wall 105, the upper wall
(not shown in Fig), and an interior bottom wall 202 of the storage
space 30, are also formed from sheet metal joined together.
However, in order to reduce the costs and manufacturing time, it is
preferable to not have to provide insulation within the walls of
the cabinets. Rather, it is beneficial to create a separate
insulation system that may be efficiently and cost-effectively
constructed independently of the cabinet walls.
The insulation panels 112 are provided to protect and insulate the
mobile cabinet 10 from impacts with external objects, as well as
protect external objects (e.g., walls and doors), and to minimize
temperature changes in the storage space 30. The heating or cooling
module 20 is provided above the storage space and is able to push
heated or cooled air into the storage space 30.
As shown in FIG. 2, the upper insulation panels 112a and 112b are
provided on the left side wall 104a and the right side wall 104b,
respectively, at a location below the heating or cooling module 20.
The left and right side walls 104a-b may be formed of aluminum or
stainless steel, in order to reflect heat within the storage space.
The particular height of the insulation panels 112 may be adjusted
based on the overall height of the mobile cabinet 10. For example,
as shown in FIG. 2, the insulation panels 112a-d each may be
provided to cover about 50% of the height of the walls of the
mobile cabinet 10. This size is only exemplary, and depends upon
the particular size of the mobile cabinet 10. For example, the
insulation panels may span the entire height and/or width of the
side walls 104a and 104b, or only a portion thereof.
Upper and lower insulation panels of different heights may be
provided to accommodate a range of different sizes of cabinets
without having to produce insulation panels with specific sizes for
each size of cabinet. As shown in FIG. 2, the panels may be
manufactured separately from the cabinet, and secured to the
cabinet in the final stages of assembly. The insulation panels may
also be added as an after-market addition to inefficient
cabinets.
The insulation panels 112a-d may also be configured to extend
beyond the width of the side walls 104a and 104b. As shown in FIGS.
3-6, the insulation panels 112 may include a flange portion 126.
The flange portion 126 extends beyond the front end of the side
walls 104a and 104b and wraps around the front corners of the
mobile heated or refrigeration cabinet 10. As such, the insulation
panels cover a portion of the front of the cabinet that is not
covered by the door. When users of the cabinet engage the door,
they are more likely to come into contact with this portion of the
cabinet. As such, the flange portion provides important protection
to the user to prevent possible burns. The flange also improves the
insulation provided at this portion of the cabinet.
As shown in FIG. 2, the door 40 preferably includes a latch
mechanism 108 comprising a striker which engages a corresponding
receptacle formed in the side wall 104a. A cabinet may also be
provided with multiple doors, which provide access to a portion of
the storage space to reduce heat loss in cabinets which are
accessed frequently. Preferably, at least two hinges and are
provided to secure the door 40 to the side wall 104b. Depending
upon the size of the mobile cabinet 10, three or more hinges may be
provided. Furthermore, the flange portions 126 of the insulation
panels 112b and 112d may include indentations to allow for the door
hinges. The door 40 engages a door flange, which is disposed within
the storage space 30 at such a position as to allow the door 40 to
be flush with edges of the side walls 104a and 104b when the door
40 is closed. A door gasket may be attached to the side of the door
flange which faces the door 40. The door gasket is compressed when
the door 40 is closed and maintained in a compressed state by the
engagement of the striker with the receptacle. This arrangement
provides an effective barrier between the storage space 30 and the
external environment, thus mitigating, if not preventing, air
migration around the periphery of the door 40 when the door is
closed.
As shown in FIGS. 1 and 2, the cabinet 10 also includes a user
interface 110 which, in the preferred embodiment, is provided on
the front of the cabinet in the heating or cooling module 20. The
user interface 110 includes temperature controls which allow a user
to raise or lower the temperature within the storage space 30. The
user interface 110 may also include a writable surface area,
preferably a dry erase surface, on which a user can display
relevant messages, such as the contents of the mobile cabinet
10.
As shown in FIGS. 1 and 2, the exemplary mobile cabinet 10 includes
a plurality of casters 118a, 118b, 118c, and 118d attached to the
bottom wall of the cabinet (e.g., bottom of storage space). The
plurality of casters 118a, 118b, 118c, and 118d allow the mobile
cabinet 10 to move in any direction. While the plurality of casters
118a, 118b, 118c, and 118d may be directly attached to the bottom
wall of the cabinet 10, the plurality of casters 118a, 118b, 118c,
and 118d may also be attached to caster mounting brackets which in
turn are connected to the bottom wall of the storage space and/or
to the side walls 104a and 104b. The casters or caster mounting
brackets may be connected to the bottom wall of the cabinet and/or
the side walls 104a and 104b by any number of fasteners including,
for example, rivets, nuts and bolts, and screws.
Each of the insulation panels 112 may be attached to the mobile
cabinet 10 by any number of fasteners including, for example, nuts
and bolts, rivets, and screws. The insulation panels may be formed
with a plurality of mounting portions 135 to allow fasteners to
engage with both the insulation panels and the cabinet body. The
mounting portions 135 are preferably provided in at least the
flange 126. In addition, mounting portions 135 may be in the rear
wall section 116.
As shown in FIG. 3, insulation panels 112 may be initially formed
as a flat, unfolded panel with an integral hinge 130 between the a
side wall section 114 of the insulation panel and a back wall
section 116 of the insulation panel. The hinge 130 may be formed as
part of a solid structure integrally molded with the side wall
section 114 and the back wall section 116. When flat, angled
portions of the side wall section 114 and the back wall section
116, near the hinge, form a V-shaped gap that defines an angle of
about 90 degrees. The side wall portion 114 may be integrally
formed with the flange portion 126, which extends in a direction
substantially perpendicular to the side wall section, in order to
protect the portion of the front of the cabinet that is not
protected by the door 40 from heat loss. The flange 126 also
protects a cabinet user from potential burns.
As shown in FIG. 4, the integral hinge 130 allows the side wall
section 114 and the back wall section 116 of the insulation panel
to be folded. When folded, the insulation panel may be secured to
the side and rear walls of the cabinet without any significant
exposed surfaces. In the exemplary embodiment, the outer corners
140a-b of the insulation panels are generally rounded, so as to
protect the mobile cabinet 10, and any object it may collide with,
regardless of the angle of impact. The outer corners 140a and 140b
may extend beyond the exterior dimensions of the insulation panels
112 or, may have the same exterior dimensions equal to the width of
the insulation panels 112. The folded insulation panel also lacks
any exposed seams that may get caught against an object such as a
door frame. As such, the hinge protects the insulation panel from
possible damage. In a preferred embodiment, the side wall section
114 and back wall section 116 of the insulation panels 112 have the
same maximum thickness, to provide substantially uniform insulation
across the surfaces of the cabinet body.
As shown in FIG. 5, the insulation panel may be provided with a
cutout (or flange) 516 on the interior edge of the rear wall
section 116. As shown in FIG. 8A, the cabinet may include a raised
channel 820 on the back of the cabinet. The raised channel 820
allows features to be secured to the cabinet without penetrating
the rear wall of the cabinet with fasteners, such as screws. The
cutout 516 in the insulation panel allows the insulation panel 112
to be secured flush to the rear channel of the cabinet.
In a preferred embodiment, as shown in detail in FIG. 6, the
insulation panels 112 are provided with a handle 150 or plurality
of handles formed as depressions within the sidewall section 114 of
the insulation panels 112, to allow the user to better control the
movement of the cabinet. In a preferred embodiment, another handle
155 may be formed within the back wall section 116 of the
insulation panels 112. The handles are formed to allow a user to
more securely engage with the cabinet when the cabinet is being
moved and provides important protection to the user to prevent
possible burns. In a preferred embodiment, the depth of the handle
is no more than half of the maximum thickness of the insulation
panels, to avoid the creation of pinch points in the blow molding
and insulation filling processes.
As further shown in a cross-sectional view of FIG. 6, the
insulation panels 112 may be formed with an outer shell 610 by a
blow molding process. The outer shell is preferably formed of
polyethylene. The outer shell 610 may then be filled with an
insulator 620, such as polyurethane foam, to help maintain the
desired temperature inside of the cabinet. In addition, mounting
portions 145 may be provided in the insulation panels 112 to allow
screws, or other fasteners, to attach the insulation panels 112
through the side and back walls of the cabinet 10. In a preferred
embodiment, the mounting portions 145 are thermally isolated from
the insulator 620, so that thermal energy is not conducted from any
screws into the insulation panels so as to degrade the insulator
620.
The insulation panels are created with a shell and insulation in a
cavity created in the shell in a multi-part process. A hinged panel
may have separate cavities formed for a side wall section 114 and a
back wall section 116. These cavities may also be injected with
polyurethane foam. The cured polyurethane foam adds additional
torsional rigidity and strength to the insulation panel.
Accordingly, a skeletal structure of the cabinet body may be less
extensive than in conventional mobile budget cabinets. Alternative
materials, instead of sheet metal, may be also used to construct
the mobile cabinet 10, such as, for example, carbon fiber,
plastics, and fiber resins composites.
FIGS. 7A and 7B show an enlarged view of the insulation panel
hinge. In this embodiment, the hinge is a double living hinge 710
formed between the side wall section 114 and rear wall section 116
of the insulation panels 112. The double living hinge 710 is
defined by two thin hinge portions 720 with a thicker portion or
web 730 there between. The preferred thickness of the hinge
portions 720 is in the range of 0.025 to 0.1 inches. More
preferably, the thickness of the hinge portions 720 is in the range
of 0.03 to 0.07 inches. In a preferred embodiment, the width of the
hinge 710 is in the range of 0.3 to 0.4 inches. Then folded, the
distance X between the angled portions 114a and 116a of the side
wall section 114 and a back wall section 116 is preferably between
0.0 and 0.5 inches, and more preferably about 0.25 inches. The thin
hinge portions 720 allow the panels 112 to be folded to be secured
to the cabinet 10. As can be understood, each of the hinge portions
720 of double living hinge 710 is independently foldable. Thus, the
side wall sections 114 and the back wall sections 116 can each move
with respect to the other, as depicted by arrows A, B and C in FIG.
7A, to enable a close fit of the folded panels 112 to the side
walls 104a, 104b and rear wall 105 of the cabinet 10. The folded
panels 112 create a rounded seamless contour along the panel
exterior, as shown in FIG. 7A. The seamless contour prevents
possible snagging and tearing of the panels 112 if the cabinet
accidentally collides with an object when being moved. As such, the
hinged insulation panels help maintain insulation qualities of the
cabinet over time.
Storage Space
FIGS. 8 and 9 illustrate the interior of the storage space 30. The
heated or refrigerated space may include a plurality of mounting
brackets which extend vertically within the storage space along the
interior portions of the side walls 104a and 104b. At least two
mounting brackets 830 may be provided along the interior portion of
each side wall 104a and 104b, with one of the mounting brackets
being located towards the front of the storage space 30, near the
door 40, and the other mounting bracket being located towards the
rear of the storage space 30. In one embodiment, the mounting
brackets located near the door 40 lie substantially within the same
plane. Similarly, the mounting brackets located near the rear of
the storage space 30 also lie substantially within the same
plane.
Each of mounting brackets 830 includes a slot which is configurable
to receive a platform support element 840, which is adjustable in
the vertical direction over the height of the mounting bracket. The
platform support element includes a support portion 860 configured
to engage a shelf or tray. A plurality of platform support elements
may be provided for each mounting bracket and engaged thereto. In
addition, a group of platform support elements disposed in
respective mounting brackets may be arranged to lie substantially
in the same horizontal plane, so as to support a shelf or tray
which rests upon the group of platform support elements.
As shown in FIGS. 8A and 8B, the side walls 104 of the storage
space 30 include a chimney 214 with an opening 204. The chimney is
located between the front and rear mounting brackets and interior
to any platform support elements provided on the interior of the
side walls. The chimney 214 allows air to flow from the heating or
cooling module down to the bottom of the cabinet; or allows air to
flow upwards from a bottom mounted heating or cooling module. In a
preferred embodiment, the chimney 214 is spaced from the side wall
104 of the cabinet, creating an air gap, in order to better
thermally isolate the air in the chimney from the insulation
panels. In a preferred embodiment, the air gap between the chimney
and the cabinet wall is at least 3/8 of an inch. When the chimney
is spaced from the side wall, the side wall of the cabinet and
insulation panels are also better able to reflect thermal energy
from the chimney back into the cabinet and protect the insulation
620 and insulation panel 112 from thermal degradation.
As shown in FIG. 9, the bottom wall 202 of the storage space 30
includes an air intake opening 204 where the chimney engages with
the heating or cooling module and an output opening 206 proximate
to the bottom of the cabinet. In a preferred embodiment, a heating
module can force heated air down through the chimney to the bottom
of the cabinet. The heated air will then rise throughout the
cabinet, as shown by the air flow arrows of FIG. 9. The air intake
opening 204 allows the heating or refrigeration system 300 to
supply the storage space 30 with air at a regulated temperature. In
the exemplary embodiment, the air intake opening 204 is
rectangular; however, other shapes may be used. As shown in FIGS.
8A and 9, the chimney 214 may be attached to the interior portion
of the side wall 104b by fasteners such as, for example, rivets,
screws, and nuts and bolts.
The heating or cooling module space 20 is designed to accommodate
the heating or refrigeration system 300. As one of ordinary skill
in the art will appreciate, the heating or refrigeration system 300
may include an AC power connection (not shown), and a control unit
320. The control unit 320 may include a power switch 1002, a
temperature controller 1006, and a thermometer 1010. As shown in
FIG. 10, the cover 1060 of the heating or cooling module space 20
may extend to cover the top on the upper insulation panels. This
allows the cover 1060 to help secure the insulation panels to the
body of the cabinet.
The cabinet may also be provided without a heating or cooling unit.
The cabinet may instead be provided with an air circulation system.
In yet another embodiment, the cabinet may be provided without any
powered component. In such an embodiment, the cabinet may be
provided with an additional top insulation panel 1112 as shown in
FIG. 11. This top insulation panel is provided in substantially the
same position as the heating or cooling module 20. The top
insulation panel is formed in the same manner as the side
insulation panels to cover the top of the cabinet.
While various example embodiments of the invention have been
described above, it should be understood that they have been
presented by way of example, and not limitation. It is apparent to
persons skilled in the relevant art(s) that various changes in form
and detail can be made therein. Thus, the disclosure should not be
limited by any of the above-described example embodiments.
In addition, it should be understood that the figures are presented
for example purposes only. The architecture of the example
embodiments presented herein is sufficiently flexible and
configurable, such that it may be utilized and navigated in ways
other than that shown in the accompanying figures.
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